Photovoltaic module with a cross rail assemby

ABSTRACT

One embodiment is a photovoltaic (PV) module including a frame to receive a perimeter of a backside of a photovoltaic (PV) laminate. The cross rail assembly may include: a conductive frame to receive a perimeter of a backside of a photovoltaic (PV) laminate; one or more conductive cross rail members provide structural rigidity to the conductive frame; and one or more pairs of couplers coupled to the conductive frame, wherein: at least one coupler comprises a grounding coupler having a first keyed section to insert into an opening in the conductive frame and a second keyed section to mate with an end of a conductive cross rail member of the one or more conductive cross rail members to ground the conductive cross rail member to the frame; or at least one coupler of at least one of the one or more pairs includes a length to define a cabling channel.

PRIORITY

The present application claims the right of priority to and benefit ofearlier filing date of U.S. Provisional Application Ser. No. 62/651,035,filed Mar. 30, 2018, and U.S. Provisional Application Ser. No.62/660,835, filed Apr. 20, 2018, each of which is hereby incorporated byreference herein in its entirety.

BACKGROUND

Photovoltaic (PV) cells, commonly known as solar cells, are devices forconversion of solar radiation into electrical energy. Generally, solarradiation impinging on the surface of, and entering into, the substrateof a solar cell creates electron and hole pairs in the bulk of thesubstrate. The electron and hole pairs migrate to p-doped and n-dopedregions in the substrate, thereby creating a voltage differentialbetween the doped regions. The doped regions are connected to theconductive regions on the solar cell to direct an electrical currentfrom the cell to an external circuit. When PV cells are combined in anarray such as a PV module, the electrical energy collected from all ofthe PV cells can be combined in series and parallel arrangements toprovide power with a certain voltage and current.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation.For the sake of brevity and clarity, every feature of a given structureis not always labeled in every figure in which that structure appears.Identical reference numbers do not necessarily indicate an identicalstructure. Rather, the same reference number can be used to indicate asimilar feature or a feature with similar functionality, as cannon-identical reference numbers. The figures are not drawn to scale.

FIG. 1A illustrates a perspective view of a bottom of a photovoltaic(PV) module that includes a PV laminate mounted on a frame.

FIG. 1B illustrates a perspective view of a roof and a mounting framefor mounting the PV module of FIG. 1A.

FIG. 2A illustrates a perspective view of a cross rail attached to a PVmodule similar to the PV module of FIG. 1A.

FIG. 2B illustrates a perspective view of a point of attachment of thecross rail to the PV laminate of the PV module of FIG. 2A.

FIG. 2C illustrates a perspective view of a point of attachment of thecross rail to a bottom lip of a long member of the frame of the PVmodule of FIG. 2A.

FIG. 2D illustrates a perspective view of a single-wall/double-walladapter as can be employed, according to some embodiments.

FIG. 3 illustrates a cross-sectional view of a PV module with a crossrail assembly, in which the cross sectional view exposes a side of thecross rail assembly, according to various embodiments.

FIG. 4A illustrates a perspective view of a cross rail assemblyincluding corner key held to a pocketed member of a frame of a PVmodule, according to various embodiments.

FIG. 4B illustrates a perspective view of a cross rail assemblyincluding a T corner key attached to segments of a member of a frame ofa PV module, according to various embodiments.

FIG. 4C illustrates a perspective view of a cross rail assemblyincluding a short corner key attached to a key slot of a member of aframe of a PV module, according to various embodiments.

FIG. 4D illustrates a perspective view of a cross rail assembly attachedto a splined hole in a member of a frame of a PV module, according tovarious embodiments.

FIGS. 5A-D illustrate a perspective view of a PV module with a crossrail assembly similar to the cross rail assembly of FIG. 4A, accordingto various embodiments.

FIG. 6 illustrates a perspective view of a PV module with a cross railassembly similar to the cross rail assembly of FIG. 4B, according tovarious embodiments.

FIGS. 7A-C illustrate a partial bottom view of a PV module with a crossrail assembly similar to the cross rail assembly of FIG. 4C, accordingto various embodiments.

FIGS. 8A-B illustrate a partial cross section view of a PV module with across rail assembly similar to the cross rail assembly of FIG. 4D,according to various embodiments.

FIGS. 8C-D illustrate a partial cross section view of yet another PVmodule with a cross rail assembly similar in some respects to the crossrail assembly illustrated in FIGS. 8A-B.

FIG. 9 illustrates a partial cross section view of a PV module with across rail assembly including a coupler (e.g. a spacer and fasteners toattach the spacer) to a frame member and a cross rail member,respectively, according to various embodiments.

FIGS. 10A-B illustrate a partial cross section view of a PV module witha cross rail assembly including a coupler (e.g. a spacer and a fastenerextending through a frame member, a spacer, and a cross rail member),according to various embodiments.

FIGS. 11A-B illustrate a front/back view and a partial bottom view,respectively, of a PV module similar to the PV module of FIG. 6 , andFIG. 11C illustrates a perspective view of a side of a frame of the PVmodule, according to various embodiments.

FIGS. 12A-I illustrates a process of assembling a PV module similar tothe PV module of FIGS. 5A-D, according to various embodiments.

FIG. 13 illustrates a bottom view of six different PV assemblies havingnon-conductive cross rail assemblies, according to various embodiments.

FIG. 14A illustrate a plan view of a photovoltaic assembly 1450,respectively, according to various embodiments.

FIGS. 14B-E illustrates a bottom view of four different PV assemblieshaving cross rail assemblies, respectively, according to variousembodiments.

FIG. 14F illustrates a perspective view of a bottom of another PVassembly having a cross rail assembly, according to various embodiments.

FIG. 15 illustrates a bottom view of another PV assembly having a crossrail assembly in which only a subset of the cross rail members isattached to the frame via a grounding coupler, according to variousembodiments.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments the application and uses ofsuch embodiments. As used herein, the word “exemplary” means “serving asan example, instance, or illustration.” Any implementation describedherein as exemplary is not necessarily preferred or advantageous overother implementations. Furthermore, there is no intention to be bound byany expressed or implied theory presented in the preceding technicalfield, background, brief summary or the following detailed description.

References to “one embodiment” or “an embodiment” do not necessarilyrefer to the same embodiment. Particular features, structures, orcharacteristics can be combined in any suitable manner consistent withthis disclosure.

Terminology. The following paragraphs provide definitions and/or contextfor terms found in this disclosure (including the appended claims):

“About” or “approximately”. As used herein, the terms “about” or“approximately” in reference to a recited numeric value, including forexample, whole numbers, fractions, and/or percentages, generallyindicates that the recited numeric value encompasses a range ofnumerical values (e.g., +/−5% to 10% of the recited value) that one ofordinary skill in the art would consider equivalent to the recited value(e.g., performing substantially the same function, acting insubstantially the same way, and/or having substantially the sameresult).

“Comprising” is an open-ended term that does not foreclose additionalstructure or steps.

“Configured to” connotes structure by indicating a device, such as aunit or a component, includes structure that performs a task or tasksduring operation, and such, structure is configured to perform the taskeven when the device is not currently operational (e.g., is noton/active). A device “configured to” perform one or more tasks isexpressly intended to not invoke 35 U.S.C. § 112, (f) or sixthparagraph.

“First,” “second,” etc. terms are used as labels for nouns that theyprecede, and do not imply any type of ordering (e.g., spatial, temporal,logical, etc.). For example, reference to a “first” IEC does notnecessarily imply that this IEC is the IEC in a sequence; instead theterm “first” is used to differentiate this IEC from another IEC (e.g., a“second” IEC).

“Based On.” As used herein, this term is used to describe one or morefactors that affect a determination. This term does not forecloseadditional factors that can affect a determination. That is, adetermination can be solely based on those factors or based, at least inpart, on those factors. Consider the phrase “determine A based on B.”While B can be a factor that affects the determination of A, such aphrase does not foreclose the determination of A from also being basedon C. In other instances, A can be determined based solely on B.

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature, and not necessarily mechanically.

“Inhibit” describes a reducing, lessening, minimizing, or effectively oractually eliminating something, such as completely preventing a result,outcome or future state completely.

The terms “a” and “an” are defined as one or more unless this disclosureexplicitly requires otherwise.

As used herein, the term “substantially” is defined as largely but notnecessarily wholly what is specified (and includes what is specified;e.g., substantially 90 degrees includes 90 degrees and substantiallyparallel includes parallel), as understood by a person of ordinary skillin the art. In any disclosed embodiment, the terms “substantially,”“approximately,” and “about” can be substituted with “within [apercentage] of” what is specified, where the percentage includes 0.1, 1,5, and 10 percent.

As used herein, “regions” can be used to describe discrete areas,volumes, divisions or locations of an object or material havingdefinable characteristics but not always fixed boundaries.

In addition, certain terminology can also be used in the followingdescription for the purpose of reference only, and thus are not intendedto be limiting. For example, terms such as “upper”, “lower”, “above”,and “below” refer to directions in the drawings to which reference ismade. Terms such as “front”, “back”, “rear”, “side”, “outboard”, and“inboard” describe the orientation and/or location of portions of thecomponent within a consistent but arbitrary frame of reference which ismade clear by reference to the text and the associated drawingsdescribing the component under discussion. Such terminology can includethe words specifically mentioned above, derivatives thereof, and wordsof similar import.

In the following description, numerous specific details are set forth,such as specific operations, in order to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to one skilled in the art that embodiments of the presentdisclosure can be practiced without these specific details. In otherinstances, well-known techniques are not described in detail in order tonot unnecessarily obscure embodiments of the present disclosure.

Photovoltaic (PV) modules can generate direct current (DC) power basedon received solar energy. PV modules can include several solar or PVcells electrically coupled to one another allowing the PV cells tocontribute to a combined output power for a PV module. Some PV modulesinclude a PV laminate encapsulating solar cells and a rectangular frameon which a perimeter of the PV laminate 105 is mounted. FIG. 1Aillustrates a perspective view of a PV module including a frame (e.g., ametal frame) with a first side on which the perimeter of the PV laminate105 is mounted, and a second opposite side. The frame includes a firstframe member 101, a second frame member 102, a third frame member 103,and a fourth frame member 104.

A PV module can be mounted on mounting rails of a mounting frame, whichcan be located on a roof in some applications. FIG. 1B illustrates aperspective view of a mounting frame 121 located on a roof 120. Thesecond side of the mounting frame (FIG. 1A) can contact the mountingframe 121. Depending on installation requirements and/or application,either the second side of the long members 101 and 102 of the frame(FIG. 1 ) can contact the mounting frame 121, or the second side of theshort members 103 and 104 of the frame (FIG. 1 ) can contact themounting frame 121.

Referring now to FIG. 2A, some PV modules can include at least one crossrail 210. The use of one or more cross rails 210 can inhibit cellcracking in the PV modules. Also, the use of one or more cross rails 210can enable different dimensions and materials to be used with the frameand/or the PV laminate 205 (e.g., a lighter frame, a thinner PV laminateand/or a PV laminate with a different combination of layers). In theillustrated example, the cross rail 210 extends from a first long member201 of the frame to a second long member 202 of the frame; however, inother examples a longer and/or heavier cross rail 210 can extend from afirst short member 203 of the frame to a second short member 204 of theframe.

The cross rail 210 can also include metal, and as such, building codescan require that the cross rail 210 to be grounded to the frame. In somePV modules, this continuous material path requirement can be addressedby running the cross rail 210 immediately against the inside of theframe. Screws or rivets can be used to achieve continuity—these can bescrewed or inserted into the frame. FIG. 2B illustrates an example inwhich a rivet is inserted through a top flange of the cross rail 210 andthe frame 201 (and/or through a PV laminate). FIG. 2C illustrates anexample in which a rivet is inserted through a bottom flange of thecross rail 210 and a bottom flange of the frame 201.

In some applications, the PV module can include various othercomponents. DC power generated by the PV module can be converted to ACpower through the use of a power inverter. The power inverter can beelectrically coupled to an output of the PV module (an output of the PVmodule can include electrical connections protruding from a backsheet ofthe PV laminate—these electrical connections can also be encapsulated bya junction box in some examples). Intervening wiring (e.g., DC-4connectors) can be used between the PV module, junction box and thepower inverter. The power inverter can be electrically coupled to the DCoutput of the PV module (e.g., the PV cables). The power inverter can belocated physically apart from the PV module, with only the interveningwiring and/or accessories thereof physically coupling the PV module tothe power inverter.

During installation of PV modules with no cross rails, the PV module canbe positioned in any configuration on the mounting frame, and the PVcables can be installed between the mounting frame (FIG. 1B) and the PVlaminate (FIG. 1A). This makes installation easy for installers, andallows application requirements—not cabling requirements—to drive theselection of a position of the PV module on the mounting frame.

In contrast, installation of PV modules with one or more cross rail canbe problematic. If a desired position of the PV module would cause thecross rail to form a “double wall” with the mounting frame, that desiredposition cannot be accomplished by the installer (it is against code toroute the PV cables under the “double wall” (e.g., under the mountingframe). For this reason, installers and/or consumers can disfavor PVmodules with cross rails.

While a PV module can include short cross rail members to allow a cableto be strung between a mounting rail and the short cross rail membereven when one of the short cross rail members is mounted over, andparallel with, a mounting rail of a mounting frame, a mechanicalstrength of such a design is not necessarily compatible with some PVlaminates and/or some PV frames. Further, mechanical strength and/orvolume of material used for such a cross member can be sub-optimal dueto beam inertia being proportional to its height cubed. Some embodimentsdisclosed herein can include a cross rail assembly including a crossrail member that is taller than such a short cross rail member (e.g., astall as members of the frame or at least taller than the short crossrail member under which cabling can be strung). Such a cross railassembly can include one or more sections to define one or more channelsthrough which cables can be strung even when the cross rail assembly ismounted over, and in parallel with, a mounting rail. In embodiments inwhich the cross rail assembly includes a metal cross rail memberattached to the frame using a pair of spacers to define the channel, themetal cross rail member can be electrically connected to the frame onlythrough the pair of spacers.

One embodiment can include an apparatus having a frame to receive aperimeter of a backside of a photovoltaic (PV) laminate; one or morecross rail members can provide structural rigidity to the frame; and oneor more pairs of couplers can be coupled to the frame, each coupler ofthe pair including a first section to define a channel and a secondkeyed section inserted into a different end of a corresponding crossrail member of the one or more cross rail members; wherein each crossrail member can be electrically connected to the frame only through thecouplers of a corresponding one of the one or more pairs.

One embodiment can include an apparatus having a cross rail assembly tobe used in a photovoltaic (PV) module. In an example, the apparatus caninclude a PV laminate having a front side, a back side, and a pluralityof solar cells encapsulated between the front side and the back side; aframe, wherein a perimeter of the PV laminate is mounted on the frame.The cross rail assembly can provide structural rigidity to the PVlaminate and the frame. The cross rail assembly can include a pluralityof sections, and a height of one or more of the sections can be lessthan a height of the remaining section(s). If the cross rail assembly isplaced over a mounting rail at an installation site, a tunnel can beformed by one or more sections of the cross rail assembly and one ormore respective regions of the mounting rail. An installer can stringcabling through the one or more tunnels. Other embodiments can bedisclosed and/or claimed.

One embodiment is an apparatus for use in a photovoltaic (PV) assembly,the PV assembly including one or more mounting rails and a PV moduleincluding a frame and a PV laminate having a front side, a back side,and a plurality of solar cells encapsulated between the front side andthe back side, wherein a perimeter of the PV laminate is mounted on theframe. The apparatus includes one or more cross rail assemblies toprovide structural rigidity to the PV laminate and the frame, each crossrail assembly extending from a first member the frame to a second memberof the frame, the cross rail assemblies grounded to the frame and havinga first side facing the back side of the PV laminate and a secondopposite side. At least one of the one or more cross rail assembliesincludes one or more first sections having one or more heights that areless than height(s) of remaining sections of the at least one cross railassembly, wherein the one or more first sections of the at least onecross rail assembly define one or more channels. The one or morechannels comprise one or more tunnels when the at least one cross railassembly is mounted over, and in parallel with, a mounting rail of theone or more mounting rails. Other embodiments can be disclosed and/orclaimed.

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter of theapplication or uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description.

FIG. 3 illustrates a cross-sectional view of a PV module 300 with across rail assembly 310, in which the cross sectional view exposes aside of the cross rail assembly 310, according to various embodiments.The PV module 300 includes a PV laminate 305, a first frame member 301(e.g., a long side frame member), a second frame member 302 (e.g., along side frame member), a third frame member 303 (e.g., a short sideframe member), and a fourth frame member (not shown). The cross railassembly 310 includes a first section 311 and a second section 312. Thecross rail assembly 310 includes a first side 321 facing the PV laminate305, and a second opposite side 322. In the first section 311, thesecond side 322 can define a channel 320, e.g., a cabling channel. Insome embodiments, the channel 320 can include a cable management featurethat can be used for cabling (not shown) to be strung through thechannel 320 by an installer. In any embodiment, the cross rail assembly310 can have a third section (not shown) similar to the first sectionbut on the other end of the cross rail assembly 310 to provide channel320 on both sides.

In the illustration, the cross rail assembly 310 is shown as in contactwith the back side of the PV laminate 305. In embodiments in which thecross rail assembly 310 is in contact, with the PV laminate 305 (e.g.,at 321 as shown), an adhesive can be located between the cross railassembly 310 and the back side of the PV laminate 305, which can serveto limit deflection in both upward and downward loading. Also, in someembodiments, only the second section 312 is in contact with the PVlaminate 305. For instance, for ease of installation, the first section311 can define an additional channel (not shown) similar to channel 320between the PV laminate and the first section 311. In some embodiments,the additional channel, which can eliminate left and right handdesignations in a parts list for the cross rail assembly 310, can bereferred to as a “dummy” channel because all cabling can be strungthrough the channel 320.

The cross rail assembly 310 can include any conductive cross rail memberand any pair of any grounding couplers described herein. Referringbriefly to FIG. 5A, some conductive cross rail member 551 may span onlya portion of the distance between long side frame members 533 and 534.One of the couplers of the pair 532 of FIG. 5A may span the reminder ofthe distance to define a cabling channel. The other coupler of the pair532 may be different, e.g., may not define a cabling channel.

Referring again to FIG. 3 , in other embodiments, the cross railassembly 310 can include a conductive cross rail member spanning anentire distance between the first frame member 301 and the second framemember 302. FIG. 4D illustrates a perspective view of a cross railassembly including a conductive cross rail member 454 to span an entiredistance between opposite members of a frame. In these embodiments, theconductive cross rail member 454 can penetrate an opening 471, e.g., aspine opening, in a frame member. As will be explained later in greaterdetail, the conductive cross rail member 454 can be grounded to theframe by the grounding coupler or by the interface between the ends ofthe conductive cross rail member 454 and an interior of the frame member

Referring once again to FIG. 3 , the second section 312 is illustratedas having a second side in a different plane than a second side of theframe (which reveals the third frame member 303); however, in otherexamples second section 312 can have a second side in a same plane as asecond side of the frame. In particular, the second section 312 can haveany height that is greater than the height of the first section 311 andno greater than the height of the frame. Accordingly, the PV module 300can be mounted over, and in parallel with, a mounting rail. The PV panel300 can be compatible with a wide variety of PV laminate designs and/orframe designs, can be light weight, and can be inexpensive tomanufacture and/or install.

A shape of the channel 320 is shown as a rectangular; however, in otherembodiments the channel 320 can have any shape that is operable forstringing cabling through the channel 320 during installation. Also, inthe illustrated example, the channel 320 is defined by the first section311 of the cross rail assembly 310, the first frame member 301, and thesecond section 312 of the cross rail assembly 310. In other examples,the channel 320 can be defined by only the first section 311 and thefirst frame member (as in a curved channel 820, shown in FIG. 8A). Inother examples, it can be possible and practical to define the channel320 in only the first section 311 (e.g., the channel 320 need notnecessarily be defined by a side of the first member 301).

The first frame member 301 can be a long side frame member of arectangular frame in some embodiments. In other embodiments, the firstframe member 301 can be a short side frame member of a rectangularframe.

FIG. 4A illustrates a perspective view of a cross rail assemblyincluding a cross rail 451 and a corner key 432 held to a pocketedmember of a frame 401 of a PV module, according to various embodiments.FIG. 4B illustrates a perspective view of a cross rail assemblyincluding a cross rail 452 and a T corner key 433 attached to segmentsof a member of a frame 402 of a PV module, according to variousembodiments. FIG. 4C illustrates a perspective view of a cross railassembly including a cross rail 453 and a short corner key 434 attachedto a key slot of a member of a frame of a PV module, according tovarious embodiments. FIG. 4D illustrates a perspective view of a crossrail assembly including a cross rail member 454 attached to a splinedhole 471 in a member of a frame of a PV module, according to variousembodiments.

FIGS. 5A-D illustrate a PV module 500 with a cross rail assembly similarto the cross rail assembly of FIG. 4A, according to various embodiments.Referring to FIG. 5A, a PV module 500 includes a PV laminate 505, whichcan be similar to any PV laminate described herein. In this embodiment,components such as a microinverter, a junction box, or the like, can bemounted on a backside of the PV laminate 505. The PV module 500 alsoincludes a cross rail assembly, which can be similar to any cross railassembly described herein. The cross rail assembly includes a cross railmember 551 and a pair 532 of couplers. The cross rail member 551 can beelectrically connected to the frame through the pair 532 and/or one ormore of the couplers of the pair 532, e.g., electrically connected tothe frame only through the pair 532. In FIG. 5A, electrical cabling isrouted in a volume defined by the frame and the cross rail member 551 sothat the cables do not impede contact between the cross rail member 551(or the frame) and the mounting frame 121 (FIG. 1B) and/or the roof 120(FIG. 1B) and can also simplify installation/assembly/transport.

Referring to FIG. 5B, a coupler 552 of the pair 532 (FIG. 5A) isillustrated. This coupler 552 can include a first projection 581 and asecond projection including an end 582. In an example, the firstprojection 581 and the second projection can be arranged in an L shape.The end 582 can be formed (e.g., keyed, molded, extruded) to mate with acavity in an end of the cross rail member 551.

The frame member 501 includes an opening 571 providing access to acavity. The cavity can be defined by an interior wall and an exteriorwall of the frame member 501. The first projection 581 can be located inthe cavity and keyed to mate with the cavity. In an example, locatingthe first projection 581 in the cavity can lock the first projection 581in position at the cavity. Locating the first projection 581 in thecavity can be performed after insertion into the opening 571.

Referring to FIG. 5C (which is a section view looking perpendicular tothe cross rail assembly and parallel to the frame member 501), thecoupler 552 can define channels 520 and 521. In this view, across-sectional view of a frame portion and a plan view of the coupler552 is shown. In this example, channel 520 can be used to string cablingduring installation of the PV module 500 (FIG. 5A). In contrast, thechannel 521 can be a dummy channel in some examples (it can be anartifact of manufacturing coupler 552 without any left/right partdesignations, not intended to be used for stringing cabling). Of course,channel 521 can be a dummy channel for some PV module 500 installconfigurations or can receive cabling in other PV module 500 installconfigurations, depending on applications. In this example, coupler 552and the frame member 501 flange corresponding to channel 520 define acable management feature. Also, the interior sidewall of the framemember 501 can also define cable management features for hanging cablingstrung through the channel 520.

Regarding the electrical connection to the frame through the pair 532(FIG. 5A, e.g., only through the pair 532), FIG. 5C, in particular,illustrates the “metal on metal” contact (which may also be referred toas contact optimized for electrical grounding) between the coupler 552and the inside of the frame member 501 (specifically with an inside ofan exterior wall of the frame member 501). While an exterior of theframe member 501 can be anodized to prevent corrosion (which involves alayer of a relatively poor conductor such as an oxide on an anodizedsurface), the inside of the frame member 501 may not be anodized. Forthis or other reasons, an electrical resistivity of the surface of theoutside of a frame member (e.g., a hollow frame member) may be greaterthan an electrical resistivity of the surface of an inside of the framemember. Therefore, the “metal on metal” can refer to contact betweennon-anodized surfaces of metal components. In some examples of PVmodules, metal fasteners are required to puncture an anodized surface tomeet grounding requirements, which may not be required due to thecontact on the inside of the frame member 501.

FIG. 5D illustrates a perspective view of a cross section through thecoupler 552 (e.g., a section view looking perpendicular to the framemember 501 and parallel to the cross rail assembly). The end 582 of thesecond projection of the coupler 552 is shown within a cavity defined bythe coupler 552 (in some examples, the coupler 552 can be double walled,similar to the frame member 501). The opening 571 is referred to as a“key pocket” in this view.

In any embodiment described herein, the frame members can be singlewalled or double walled (similar to frame member 501 of FIG. 5B), andthe cross rail assembly can be single walled or double walled. Also, insome embodiments of PV module having frame members and a cross railassembly, the number of walls of the cross rail assembly need not be thesame as the number of walls of the frame members. An adapter can be usedto attach, say, a single walled cross rail assembly to a double walledframe member. FIG. 2D illustrates a perspective view of asingle-wall/double-wall adapter as can be employed, according to someembodiments. This or any other feature of U.S. Provisional ApplicationSer. No. 62/651,035 can be used in any embodiment of a photovoltaicmodule with a cross rail assembly described herein. In particular, anyfeatures of this adapter can be employed on any coupler (e.g., groundingcoupler) described herein, to provide a coupler (e.g., groundingcoupler) to attach a single or double walled cross rail member to adouble or single (respectively) walled frame.

In an embodiment, this connecting key 210 of FIG. 2D is a single-wallkey with two connecting holes 213. In an embodiment, the single-wall keycan be a single-wall aluminum key. Other materials, such as galvanizedsteel, or carbon laminate, or polymers, can also be used. Additionally,one connecting hole, or more than two connecting holes, such as 3, 4, 5,or more connecting holes, can be employed in embodiments. Theseconnecting holes 213 can be used to secure the key to a single wallframe section during manufacture. In an example, the connecting holescan instead be referred to as screw holes, and screws can be used asconnectors; however, the connecting holes can have other configurations,such a rod-hole combination, a pin-hole combination, a rivet-holecombination, a tox-hole combination, and a tab- or flange-slot/recesscombination, and combinations thereof.

Also labelled in FIG. 2D are an open-end hollow 214, pinching ends 217,long key arm 219, optional key hollows 211, 212, 220, short key arm 218,and edge key arm 216. In some embodiments, the connecting key can havetwo short key arms, two long keys arms, three or more key arms (such aswhen connecting three or more frame sections together), a long key armand a short key arm, and various permutations of these examples. Asnoted above, the connecting holes 213 can be threaded to accept screwsand can also be sized or configured for other connectors, e.g., pins,rods, rivets, tox connectors, etc. Other connection techniques can beused, such as a flange-slot/recess combination or a tab-slot/recesscombination.

In embodiments, connecting keys can join a cross rail assembly and framesections at various angles that can include: 11.25°, 22.5°, 45°, 60°,75°, 90°, 110°, 115°, 125°, 135°, and 180°. The frame sections can bemade from various materials and can include a metal of sufficientrigidity. In embodiments, the connecting keys and frame sections can begalvanized or otherwise treated to resist weathering.

FIG. 6 illustrates a perspective view of a PV module 600 with a crossrail assembly similar to the cross rail assembly of FIG. 4B, accordingto various embodiments. The PV module 600 includes a cross rail member651, which can be similar to cross rail member 551 (FIGS. 5A-D). Thecross rail member 651 can be electrically connected to the frame of thePV module 600 through the pair 632 of couplers, e.g., in some examplesonly through the pair 632 of couplers.

An exploded view of one of the couplers illustrates first, second, andthird projections arranged in a T shape. For example, the cross railassembly can be positioned perpendicular to the frame, as shown. In anexample, one of the projections that define the channels can have akeyed end, similar to the end 582 (FIG. 5B).

In this example, the frame member is segmented. One of the projectionsis keyed and located in a cavity of one segment of the frame member. Theother one of the projections is also keyed and located in a cavity ofthe other segment of the frame member. In other words, the coupler alsocouples the frame member segments together, besides coupling the crossrail member to the frame. The coupler can have a “metal to metal”contact, similar to the “metal to metal” contact described with respectto FIG. 5D.

FIGS. 7A-C illustrate a partial bottom view of a PV module with a crossrail assembly similar to the cross rail assembly of FIG. 4C, accordingto various embodiments. This coupler 732 is referred to as a “shortkey.” Again, the cross rail member 751 can be electrically connected tothe frame through a pair of couplers, e.g., in some examples onlythrough the pair of couplers. A “metal on metal” contact similar to the“metal on metal” contacts described previously, can be defined withinthe keyway and the corresponding region of the short key 732.

The short key 732 can be L or T shaped, and can include a projectionthat defines the channel (referred to in this example as DC cable passthrough room) and includes a keyed end to mate with a cross rail keywaydefined by the cross rail member 751. The other projection(s) can matewith a frame member keyway defined by the frame member 701. FIGS. 7B and7C illustrate cross sections of the frame member 701 and the cross railmember 751, respectively. The keyways can be approximately half theheight of the associated members (which can be the same height in thisexample), but can be other proportions in other examples. As shown bythe cross sections, in this example the frame member 701 can be doublewalled and defining a keyway, and the cross rail member 751 can be an Istructure and defining a keyway.

Also, the cavity defined by each keyway (to mate with the keyed regionsof the coupler 732) can have dimensions greater than the openings in thekeyways, as shown. A sidewall of the keyway defining this opening can besheared off (in only a selected section of the keyway) duringinstallation to dispose the keyed regions into the cavity. The keyedregions then can be slipped into the cavity, and a remaining section ofthe keyway (in which the sidewall is not sheared off) can secure thecoupler into the members.

FIGS. 8A-B illustrate a partial cross section view of a PV module with across rail assembly similar to the cross rail assembly of FIG. 4D,according to various embodiments. In this view, a cross-sectional viewof a frame portion and the cross rail member 851, is shown. In thisexample, the cross rail assembly includes a cross rail member 851 tomake physical contact with the frame member 801. An end of the crossrail member 851 makes a metal on metal contact inside a cavity in theframe member 801. Also, the cross rail member 851 and the frame member801 define a cabling channel (e.g., DC cable pass through).

Referring to FIG. 8B, the opening in the frame member 802 can be aspline. The cross section of the cross rail member 852 includes adistorted I shape (as shown, wherein opposite sides of the top andbottom of the I are non-parallel with the other sides of the top andbottom). This shape allows the cross rail member 852 to be turned forinsertion into the spline shaped opening, and then twisted to lock intoplace.

FIGS. 8C-D illustrate a partial cross section view of yet another PVmodule with a cross rail assembly. In this example, the cross railmember 853 does not define any channel. However, the cross rail member853 still includes the metal on metal contact (e.g., with a lowerresistivity surface of the frame member 803) and the locking features tomate with opening 871 in the frame member 803, and for these reasons therivets required by some PV modules may not be required (due to the metalon metal contact on the non-anodized area and the locking feature).

FIG. 9 illustrates a perspective view of a partial cross section view ofa PV module with a cross rail assembly including a coupler 932 (e.g. aspacer and fasteners to attach the spacer) to a frame member 901 and across rail member 951, respectively, according to various embodiments.In this example, the fasteners can puncture a surface (e.g., an anodizedsurface of bottom flanges) of the members 901 and 951 to providecontinuity between the cross member 951 and the frame 901 (from thecross rail member 951, through a fastener, through the spacer, throughthe other fastener, to the frame member 901).

The spacer 932 can include a projection (such as a prong) to wedge fitthe spacer into position, to hold the spacer 932 while the fasteners areinstalled. In this example, the projection mates with an approximately270 degree circle formation on an interior wall of the frame member 902.In other examples, the frame member 902 need not include the circleformation and the projection can be longer and engage a backside of thePV laminate to wedge the spacer into position. In this example, thespacer 932 has an arithmetic spiral segment shape (similar to anautilus), where an end for a smallest turning of the spiral segmentdefines a cable management feature (and another region of the spiralsegment, such as the rest of the spiral segment, defines the channel).In other examples, the spacer can have any shape, such as a U shape(bottom of U facing PV laminate), and may or may not include aprojection extending into the channel for cable management.

FIGS. 10A-B illustrates a partial cross section view of a PV module witha cross rail assembly including a coupler 933 (e.g. a spacer and afastener extending through a frame member 902 and a cross rail member952), according to various embodiments. In this example, the head of thefastener can provide metal on metal contact with an interior wall of theframe member 902, and also can puncture any anodized surface on an otherside of the interior wall. The fastener can also puncture the end of thecross rail member 952.

The exterior wall of the frame member 902 can include an opening (notshown) sized for the head of the fastener to install the fastener fromthe outside of the PV module. The spacer can include small projectionsas illustrated to engage mating cavities on the end of the cross railmember 952, which can align the spacer for installation of the fastenerinto a predrilled hole between the mating cavities.

In this example, a spring can be coupled to the PV module asillustrated. In a released position, the spring can block access to thechannel. The spring can be actuated to insert cabling into the channel,and then can spring back into the original position. The illustratedspring can be utilized as a cable management feature for the channel ofany other PV module described herein. Other examples may note require aspring—the force of gravity may be sufficient to restore a cablemanagement component (e.g., a closing tab) back to its initial stateafter cables are inserted.

FIGS. 11A-B illustrate a PV module similar to the PV module of FIG. 6 ,according to various embodiments. As illustrated, the PV module caninclude frame member segments 1101 and 1102 joined end to end to form,say, long sides of the frame, as shown in FIG. 11C. The frame segments1101 and 1102 can be joined to the cross rail member 1152 by the Tshaped coupler 1131, shown in more detail in FIG. 12B. In some examples,a cover can be used as illustrated to protect the PV laminate and fillin any gaps between the frame segments 1101 and 1102 (although in someembodiments the ends of the frame segments 1101 and 1102 can be inphysical content leaving substantially no gap). The channel and thecoupler 1131 in the channel can be covered (e.g., protected from theelements) by the PV laminate.

FIGS. 12A-I illustrates a process of assembling a PV module similar tothe PV module of FIGS. 5A-D, according to various embodiments. Shortside frame members 1203 and 1204 can be placed on a backside of the PVlaminate 1205 (or vice versa, e.g., PV laminate 1205 can be placed onthe short side frames 1203 and 1204), as shown in FIGS. 12A-B. Couplers1231 (e.g., L shaped couplers in this embodiment) can be inserted intoan opening 1207 defined by interior sidewalls of long side frame members1201 and 1202 (by moving the coupler 1231 toward the exterior sidewalls,through the opening 1207), as shown in FIG. 12C.

A keyed projection of the coupler 1231 can then be inserted into acavity between the sidewalls by moving the coupler 1231 in an orthogonaldirection (parallel with a length of the long side frame member 1201),as shown in FIGS. 12D-F. This can lock the coupler 1231 into place. Across rail member 1251 can be slipped over a keyed end of the otherprojection of the coupler 1231 (this can be performed before insertingthe coupler 1231 into the long side frame member 1201, in someexamples).

With the couplers 1231 in place, the assembly of the long side framemembers 1201 and 1202, the couplers 1231, and the cross rail members1251 can be placed on the backside of the PV laminate 1205. This caninclude initially inserting corner keys 1299 into the short side framemembers (as shown in FIGS. 12G-I for frame member 1204), and thenslipping the long side members 1201 and 1202 over the other projectionsof the corner keys 1299. The PV module can then be transported to aninstallation site, where an installer can string cable through thechannels.

FIG. 13 illustrates a bottom view of six different PV assemblies 1351,1352, 1353, 1354, 1355, and 1356 having non-conductive cross railassemblies 1361, 1362, 1363, 1364, 1365, and 1366, respectively,according to various embodiments. Non-conductive cross rail assemblies1361, 1362, 1363, 1364, 1365, and 1366 can be manufactured using anyknown molding, casting, and/or forming processes. In some embodiments,the non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365,and 1366 can include non-extruded components (e.g., only non-extrudedcomponents). In some embodiments, non-conductive cross rail assemblies1361, 1362, 1363, 1364, 1365, and 1366 can include plastic.

Non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and1366 can limit the bending under load of the PV laminate 1305 bystiffening the PV laminate 1305, e.g., each can shorten the distancefrom two frame-supported parts of the PV laminate 1305, e.g., can createadditional load paths between the PV laminate 1305 and a mounting systemcomponent, such as mounting rails 1399. In some embodiments,non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365, and1366 can have a height greater than a selected value (e.g., half of thedistance between the back side of the PV laminate 1305 and a plane of abottom of the frame) to provide this stiffening. Non-conductive crossrail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 can be attachedto a backsheet of the PV laminate 1305 using, for example, an adhesivesimilar to other embodiments of cross rail assemblies described herein.

Also, any of the non-conductive cross rail assemblies 1361, 1362, 1363,1364, 1365, and 1366 can contact mounting system components, such asmounting rails 1399. In some embodiments, any of the non-conductivecross rail assemblies 1361, 1362, 1363, 1364, 1365, and 1366 candistribute contact force from mounting system components through agreater region of the PV laminate 1305. Other embodiments of anon-conductive cross rail assembly can have any shape to transfer theload between mounting system components and the PV laminate 1305laminate in downforce.

The non-conductive cross rail assemblies 1361, 1362, 1363, 1364, 1365,and 1366 can define cabling gaps 1371, 1372, 1373, 1374, 1375, and 1376with the frame 1301, e.g., with long side members of the frame 1301. Inthe illustrated embodiments, the cabling gaps 1371, 1372, 1373, 1374,1375, and 1376 are also defined by a backside of the PV laminate 1305.In other embodiments, a conductive cross rail assembly can have any ofthe illustrated shapes of non-conductive cross rail assemblies 1361,1362, 1363, 1364, 1365, and 1366 and additionally can include a sectionsimilar to section 311 (FIG. 3 ) and/or can include a separate component(such as any conductive spacer described herein) to electrically couplethe conductive cross rail assembly to a frame of the PV assembly. Inthese embodiments, the conductive cross rail assembly and/or theadditional component can define a cabling channel with the frame. Also,conductive cross rail assemblies can make contact with a conductivemounting rail (similar to mounting rail 1399) provide form an electricalpath (e.g., the only electrical path) between a frame of the PV moduleand the conductive mounting rail.

Shapes of any cross rail assemblies according to embodiments disclosedherein can be significantly different than a “bar” shape of the crossrail member illustrated in FIG. 2A. For instance, such a shape may ormay not be defined by elongated members at all or not at all, e.g., across rail assembly similar to non-conductive cross rail assembly 1366can include a shape not defined by any elongated members (e.g., round).Also, any cross rail member can include a round core and one or moreelongated projections extending from the round core (which may or maynot be parallel with any members of the frame, and in the case of morethan one elongated projection may not be parallel with another one ofthe elongated projections). Also, some shapes can have elongated membersthat are not parallel with any members of the frame, e.g., a cross railassembly similar to non-conductive cross rail assemblies 1364 and 1365.Also, some shapes can include elongated projections extending from apoint similar to non-conductive cross rail assembly 1361 (such as adouble cross shape with two of such points). In non-conductive crossrail assembly 1361 with elongated projections, at least one of theelongated projections is non-parallel (e.g., orthogonal) with anotherone of the elongated projections).

FIGS. 14A-14C include optional PV assemblies 1451, 1452, 1453, 1454, and1455 having cross rail assemblies 1461, 1462 a 1462 b, 1463, 1464 a, and1464 b, respectively. The PV assemblies 1451, 1452, 1453, 1454, and 1455and cross rail assemblies 1461, 1462 a 1462 b, 1463, 1464 a, and 1464 bcan provide comparable structural support to a full frame, in referenceto FIG. 1 . In an example, the cross rail assemblies 1461, 1462 a 1462b, 1463, 1464 a, and 1464 b can provide structural support that allowfor the use of partial frames, e.g., frames that are not continuousand/or include gaps between frame portions. Such PV assemblies 1451,1452, 1453, 1454, and 1455 and cross rail assemblies 1461, 1462 a 1462b, 1463, 1464 a, and 1464 b can provide substantial cost reduction incontrast to the use of full frames while providing comparable structuralintegrity you would expect in a full frame.

FIG. 14A illustrate a plan view of a photovoltaic assembly 1450,respectively, according to various embodiments. As shown, thephotovoltaic assembly 1450 can include a partial frame 1401, a pluralityof solar cells 1404, a laminate 1405 and a gap portion 1402 betweenpartial frame portions 1404. The photovoltaic assembly 1450 canrepresent a plan view for the PV assemblies 1451, 1452, 1453, 1454, and1455 described in FIG. 14B.

FIGS. 14B-E illustrates a bottom view of four different PV assemblies1451 (FIG. 14B), 1452 (FIG. 14C), 1453 (FIG. 14D), and 1454 (FIG. 4E)having cross rail assemblies 1461, 1462 a 1462 b, 1463, 1464 a, and 1464b, respectively, according to various embodiments. Referring to PVassembly 1451, the cross rail assembly 1461 can include a crossstructure which can connect at end portions of a partial frame 1401, thepartial frame 1401 including gaps 1402 between separate partial frames.Referring to PV assembly 1452, the cross rail assembly 1462 a, 1462 bcan include support portions 1462 a and a central support portion 1462b, where the support portion can be connected to end portions of apartial frame 1401 and the central portion 1462 b can connect to all thesupport portions 1462 a together. Referring to PV assembly 1453, thecross rail assembly 1463 can include a cross structure which can connectat corners of a partial frame 1401, where the partial frame can includegaps 1402, 1403. Referring to PV assembly 1454, the cross rail assembly1464 a, 1464 b can include support portions 1464 a and a central supportportion 1464 b, where the support portion can be connected to endportions and corner portions of a partial frame 1401 and the centralportion 1462 b can connect to the support portions 1462 a together.Also, the partial frame 1401 can include gaps 1401 at long sides of thePV assembly and/or can include gaps 1403 at short sides of the PVassembly.

Referring again to FIG. 14B, the cross rail assemblies 1461, 1462 a 1462b, 1463, 1464 a, and 1464 b, can be manufactured using any knownmolding, casting, and/or forming processes. In some embodiments, thecross rail assemblies 1461, 1462 a 1462 b, 1463, 1464 a, and 1464 b, caninclude non-extruded components (e.g., only non-extruded components). Insome embodiments, the cross rail assemblies 1461, 1462 a 1462 b, 1463,1464 a, and 1464 b, can include plastic. In an embodiment, the crossrail assemblies 1461, 1462 a 1462 b, 1463, 1464 a, and 1464 b, can limitthe bending under load of the PV laminate 1405 by stiffening the PVlaminate 1405, e.g., each can create additional load paths between thePV laminate 1405 and a mounting system component, such as mounting rails1399 of FIG. 13 . In one example, the cross rail assemblies 1461, 1462 a1462 b, 1463, 1464 a, and 1464 b can be non-conductive, e.g., includenon-conductive materials. In another example, the 1461, 1462 a 1462 b,1463, 1464 a, and 1464 b can be conductive, e.g., include conductivematerials.

FIG. 14F, illustrates a perspective view of the PV assembly 1455,according to various embodiments. In an example, the cross rail assemblycan include support portions 1465 a and a central support portion 1465b. In an example, the support portion 1465 a can be connected to endportions and corner portions of a partial frame 1401 (for PV laminate1405) and the central portion 1465 b can connect to the support portions1465 a together, as shown for clarity.

FIG. 15 illustrates a bottom view of another PV assembly having aconductive cross rail assembly in which only a subset of the cross railmembers is attached to the frame via a grounding coupler, according tovarious embodiments. The frame of the PV assembly includes a framemember 1501, a frame member 1502, a frame member 1503, and a framemember 1504. The cross rail assembly includes a number of cross railmembers. A grounding coupler 1532, similar to any grounding coupler,keyed adaptor, or the like, described in any example here, electricallycouples an individual cross rail member 1510 of the cross rail membersto the frame. In this example, the grounding coupler 1531 attaches thecross rail member to a corner defined by frame members 1502 and 1503(e.g., tethered to one or more frame members, such as a corner definedby frame members), but in other examples a grounding coupler for theindividual cross rail member may attach the individual cross rail memberto one of the frame members 1501-1504.

The other remaining cross rail members may be electrically coupled tothe frame only through the individual cross rail member 1510 and itsgrounding coupler 1532. The other remaining cross rail members may nothave their own couplers (e.g., the other remaining cross rail membersmay be “untethered” to the frame members and instead adhered to the PVlaminate 1505, similar to how any non-conductive cross rail membersdescribed herein may be adhered to a PV laminate). In this example, acircular cross rail member 1511 electrically couples the other crossrail members to the individual cross rail member 1510. Any of the crossrail members (including cross rail member 1510 and/or the circular crossrail member 1511) may be adhered to the PV laminate 1505, similar to howany non-conductive cross rail members described herein may be adhered toa PV laminate.

EXAMPLES

Example 1 is a photovoltaic (PV) module, comprising: a PV laminatehaving a front side, a back side, and a plurality of solar cellsencapsulated between the front side and the back side; a frame, whereina perimeter of the PV laminate is mounted on the frame; a cross railassembly to provide structural rigidity to the PV laminate and theframe, the cross rail assembly extending from a first member of theframe to a second member of the frame, the cross rail assembly groundedto the frame and having a first side facing the back side of the PVlaminate and a second opposite side; and a cabling channel defined by:an end of a member of the cross rail assembly and a grounding coupler toattach the end of the member of the cross rail assembly to one of thefirst and second members of the frame, or a first section of a pluralityof sections of the cross rail assembly, wherein a distance between thefirst side of the cross rail assembly and the second side of the crossrail assembly in the first section is less than a distance between thefirst side of the cross rail assembly and the second side of the crossrail assembly in a second different section of the plurality of sectionsof the cross rail assembly.

Example 2 includes the subject matter of example 1 or any other exampleherein, wherein the one of the first or second members of the frameincludes a cavity defined by interior one of a plurality of sidewalls ofthe one of the first or second members, and wherein the groundingcoupler extends through an opening formed in the interior sidewall.

Example 3 includes the subject matter of example 2 or any other exampleherein, wherein the grounding coupler includes first and secondprojections arranged in an L-shape, the first projection located in thecavity and the second projection defining the cabling channel. While thefirst and second projections may be arranged in an L-shape in someexamples, in other examples the first and second projections may bearranged along intersecting lines that form any angle (e.g., any obtuseangle, say less than 160 degrees in some examples, or an any acuteangle, say greater than 70 degrees in some examples).

Example 4 includes the subject matter of example 3 or any other exampleherein, wherein the second projection is fastened to the end of themember of the cross rail assembly.

Example 5 includes the subject matter of example 3 or any other exampleherein, wherein the first projection is keyed and, and wherein thecavity comprises a key pocket.

Example 6 includes the subject matter of example 2 or any other exampleherein, wherein the one of the first or second members of the frame issegmented into segments, wherein the cavity is defined by ends of thesegments, and wherein the grounding coupler includes first, second, andthird projections arranged in a T-shape, the first and secondprojections located in the cavity and the third projection defining thecabling channel. While the grounding coupler may be arranged in aT-shape in some examples, in other example angles any two projectionscan be right angles, any acute angle, any obtuse angle, etc.

Example 7 includes the subject matter of example 6 or any other exampleherein, wherein the first and second projections are keyed, and whereinthe cavity comprises a plurality of openings to make with the first andsecond projections.

Example 8 includes the subject matter of example 6 or any other exampleherein, wherein the third projection is fastened to the end of themember of the cross rail assembly.

Example 9 includes the subject matter of example 6 or any other exampleherein, wherein a first end section of the third projection is keyed,and wherein the first end section of the third projection is located ina keyway formed on an end of the cross rail, and wherein a seconddifferent section of the third projection defines the cabling channel.

Example 10 includes the subject matter of example 1 or any other exampleherein, wherein the one of the first or second members of the frameincludes a keyway defining an opening to receive a keyed projection ofthe grounding coupler, and wherein the keyed projection of groundingcoupler extends through a cavity defined by the keyway.

Example 11 includes the subject matter of example 1 or any other exampleherein, further comprising a keyed projection formed on the end of themember of the cross rail assembly, wherein the keyed projection islocated in a cavity defined by interior sidewall of the one of the firstor second members and an exterior sidewall of the one of the first orsecond members.

Example 12 includes the subject matter of example 11 or any otherexample herein, wherein the interior wall includes a spline openinghaving a first region one or more projections defining one or moresecond regions, respectively, and wherein the keyed projection islocated in only the first region of the spline opening.

Example 13 includes the subject matter of example 1 or any other exampleherein, wherein the grounding coupler a conductive spacer and one ormore conductive fasteners to form an electrical path that includes themember of the cross rail assembly and the frame.

Example 14 includes the subject matter of example 13 or any otherexample herein, wherein the one or more fasteners comprises a firstfastener and a second fastener to attach the conductive spacer to theend of the member of the cross rail assembly and the frame,respectively.

Example 15 includes the subject matter of example 13 or any otherexample herein, wherein the one or more fasteners comprises a fastenerhaving a length that is longer than a length of the conductive spacer,wherein the fastener extends through an opening in the frame, an openingin the space, and an opening in an end of the member of the cross railassembly.

Example 16 includes the subject matter of example 1 or any other exampleherein, wherein the cabling channel is defined by the first section ofthe cross rail assembly and one of the first and second members of theframe.

Example 17 includes the subject matter of example 1 or any other exampleherein, wherein the cabling channel comprise a first cabling channel,the member of the cross rail assembly comprises a first member of thecross rail assembly, the grounding coupler comprises a first groundingcoupler, the plurality of sections of the cross rail assembly comprisesa first plurality of sections of the cross rail assembly, and whereinthe PV module further comprises: one or more second cabling channelsdefined by: an end of one or more second members of the cross railassembly, respectively, and one or more second grounding couplers toattach one or more ends of the one or more second members of the crossrail assembly, respectively, to one of the first and second members ofthe frame, respectively, or one or more first sections of one or moresecond plurality of sections of the cross rail assembly, respectively,wherein a distance between the first side of the cross rail assembly andthe second side of the cross rail assembly in the one or more firstsection of the one or more second plurality of sections is less than adistance between the first side of the cross rail assembly and thesecond side of the cross rail assembly in one or more second differentsections of the second plurality of sections of the cross rail assembly,respectively.

Example 18 includes the subject matter of example 1 or any other exampleherein, wherein the first member of the frame is of a first edge of thePV module and the second member of the frame is of a second oppositeedge of the PV module.

Example 19 includes the subject matter of example 18 or any otherexample herein, wherein the frame comprises a rectangular frame, andwherein the first and second members are longer than third and fourthmembers of the rectangular frame.

Example 20 includes the subject matter of example 1 or any other exampleherein, wherein the cross rail assembly is in contact with the back sideof the PV laminate.

Example 21 includes the subject matter of example 20 or any otherexample herein, wherein the member of the cross rail assembly is adheredto the back side of the PV laminate.

Example 22 includes the subject matter of example 1 or any other exampleherein, wherein the perimeter of the PV panel contacts a first side ofthe first and second members of the frame, and wherein a distancebetween the first side of the first and second members of the frame anda second opposite side of the first and second members of the frame isthe same as the distance between the first side of the cross railassembly and the second side of the cross rail assembly in a seconddifferent section of the plurality of sections of the cross railassembly.

Example 23 includes the subject matter of example 1 or any other exampleherein, wherein the second section of the cross rail assembly isarrangable to form wall with a mounting rail of a mounting frame, andwherein the first section of the cross rail assembly and a correspondinglocation on the mounting rail defines a cabling tunnel.

Example 24 is an apparatus, comprising: a frame to receive a perimeterof a backside of a photovoltaic (PV) laminate; one or more cross railmembers provide structural rigidity to the frame; and one or more pairsof couplers coupled to the frame, each coupler of the pair including afirst section to define a channel and a second keyed section insertedinto a different end of a corresponding cross rail member of the one ormore cross rail members; wherein each cross rail member is electricallyconnected to the frame only through the couplers of a corresponding oneof the one or more pairs.

Example 25 includes the subject matter of example 24 or any otherexample herein, wherein a side of the one or more cross rail members isarranged in a same plane as a side of the frame to receive a perimeterof a backside of a photovoltaic (PV) laminate.

Example 26 includes the subject matter of example 25 or any otherexample herein, wherein an opposite side of the one or more cross railmembers is arranged in a same place as an opposite side of the frame.

Example 27 includes the subject matter of example 26 or any otherexample herein, wherein the frame comprises four members, at least oneof the frame members includes plural segments, and wherein each segmentof the segments includes an end defining one of a cavity or a projectionto mate with the other of a cavity or projection of the coupler, whereina count of the one or more pair of couplers is equal to N, and wherein acount of the segments is N+1.

Example 28 is an apparatus for use in a photovoltaic (PV) assembly, thePV assembly including one or more mounting rails and a PV moduleincluding a frame and a PV laminate having a front side, a back side,and a plurality of solar cells encapsulated between the front side andthe back side, wherein a perimeter of the PV laminate is mounted on theframe, the apparatus further comprising: one or more cross railassemblies to provide structural rigidity to the PV laminate and theframe, each cross rail assembly extending from a first member the frameto a second member of the frame, the cross rail assemblies grounded tothe frame and having a first side facing the back side of the PVlaminate and a second opposite side; wherein at least one of the one ormore cross rail assemblies includes one or more first sections havingone or more heights that are less than height(s) of remaining sectionsof the at least one cross rail assembly, wherein the one or more firstsections of the at least one cross rail assembly define one or morechannels.

Example 29 includes the subject matter of example 28 or any otherexample herein, wherein the one or more channels comprise one or morechannels when the at least one cross rail assembly is mounted over, andin parallel with, a mounting rail of the one or more mounting rails.

Example 30 includes the subject matter of example 29 or any otherexample herein, wherein the one or more cross rail assemblies compriseone or more cross rail members, respectively, wherein the one or morecross rail assemblies further include one or more pairs of couplers,each coupler of the pair attached to a different end of a correspondingcross rail member of the one or more cross rail members.

Example 31 is a photovoltaic (PV) module, comprising: a PV laminatehaving a front side, a back side, and a plurality of solar cellsencapsulated between the front side and the back side; a frame, whereina perimeter of the PV laminate is mounted on the frame; a non-conductivecross rail assembly to provide structural rigidity to the PV laminateand the frame, the non-conductive cross rail assembly extending from afirst member the frame to a second member of the frame, thenon-conductive cross rail assembly having a first side adhered to a backside of the PV laminate and a second opposite side to make contact withone or more mounting rails; and a cabling gap defined by thenon-conductive cross rail assembly, the first or second member of theframe, and the back side of the PV laminate.

Example 32 includes the subject matter of example 31 or any otherexample herein, wherein the cabling gap is further defined by an end ofan elongated member of the non-conductive cross rail assembly, whereinthe elongated member is non-parallel and non-orthogonal with the firstand second members of the frame.

Example 33 includes the subject matter of example 31 or any otherexample herein, wherein the non-conductive cross rail assembly includesa round core centered on a center of the backside of the PV laminate.

Example 34 includes the subject matter of example 31 or any otherexample herein, wherein the non-conductive cross rail assembly includesone or more projections extending from the round core.

Example 35 includes the subject matter of example 35 or any otherexample herein, wherein the non-conductive cross rail assembly includesa first elongated projection that is non-parallel with a secondelongated projection of the non-conductive cross rail assembly.

The above disclosure and examples provide a complete description of thestructure and use of illustrative embodiments. Although certainembodiments have been described above with a certain degree ofparticularity, or with reference to one or more individual embodiments,those skilled in the art could make numerous alterations to thedisclosed embodiments without departing from the scope of thisinvention. As such, the various illustrative embodiments of the methodsand systems are not intended to be limited to the particular formsdisclosed. Rather, they include all modifications and alternativesfalling within the scope of the claims, and embodiments other than theone shown can include some or all of the features of the depictedembodiment. For example, elements can be omitted or combined as aunitary structure, and/or connections can be substituted. Further, whereappropriate, aspects of any of the examples described above can becombined with aspects of any of the other examples described to formfurther examples having comparable or different properties and/orfunctions, and addressing the same or different problems. Similarly, itwill be understood that the benefits and advantages described above canrelate to one embodiment or can relate to several embodiments. Forexample, embodiments of the present methods and systems can be practicedand/or implemented using different structural configurations, materials,and/or control manufacturing steps. The claims are not intended toinclude, and should not be interpreted to include, means-plus- orstep-plus-function limitations, unless such a limitation is explicitlyrecited in a given claim using the phrase(s) “means for” or “step for,”respectively.

1.-16. (canceled)
 17. An elongated grounding coupler having a first end,a second end, and a length between the first and second ends, theelongated grounding coupler comprising: first keyed section at the firstend, the first keyed section to insert into an opening defined by aconductive frame of a photovoltaic (PV) module; and a second section atthe second end, the second section to mate with an end of a conductivecross rail member of the PV module.
 18. The grounding coupler of claim17, wherein the length comprises a slender length to define a cablingchannel with the conductive frame and the conductive cross rail member,wherein a first sidewall of the cabling channel is defined by theconductive frame of the PV module, a second sidewall of the cablingchannel is defined by the end of the cross rail member, and a bottom ofthe cabling channel is defined by the length.
 19. The grounding couplerof claim 17, wherein the second section comprises a single wall key. 20.The grounding coupler of claim 17, wherein the first keyed section isarranged to insert into a corner defined by plural conductive framemembers of the conductive frame or to insert into a length of aconductive frame member of the conductive frame.
 21. The groundingcoupler of claim 17, wherein the first keyed section is arranged toinsert into a spline opening, wherein the opening defined by theconductive frame comprises the spline opening.
 22. The grounding couplerof claim 17, wherein the opening is shaped as a splined hole.
 23. Thegrounding coupler of claim 17, wherein the conductive cross rail memberis shaped as an I beam and has at least one flange projecting at anacute angle from a central web of the cross-rail member.
 24. Anelongated grounding coupler having a first end, a second end, and alength between the first and second ends, the elongated groundingcoupler comprising: first keyed section at the first end, the firstkeyed section to insert into an opening defined by a double wallconductive frame of a photovoltaic (PV) module; and a second section atthe second end, the second section to mate with an end of a conductivecross rail member of the PV module.
 25. The grounding coupler of claim24, wherein the length comprises a slender length to define a cablingchannel with the conductive frame and the conductive cross rail member,wherein a first sidewall of the cabling channel is defined by theconductive frame of the PV module, a second sidewall of the cablingchannel is defined by the end of the cross rail member, and a bottom ofthe cabling channel is defined by the length.
 26. The grounding couplerof claim 24, wherein the second section comprises a single wall key. 27.The grounding coupler of claim 24, wherein the first keyed section isarranged to insert into a corner defined by plural conductive framemembers of the conductive frame or to insert into a length of aconductive frame member of the conductive frame.
 28. The groundingcoupler of claim 24, wherein the first keyed section is arranged toinsert into a spline opening, wherein the opening defined by theconductive frame comprises the spline opening.
 29. The grounding couplerof claim 24, wherein the opening is shaped as a splined hole.
 30. Thegrounding coupler of claim 24, wherein the conductive cross rail memberis shaped as an I beam and has at least one flange projecting at anacute angle from a central web of the cross-rail member.
 31. Anelongated grounding coupler having a first end, a second end, and alength between the first and second ends, the elongated groundingcoupler comprising: first keyed section at the first end, the firstkeyed section positioned at an end of an upright web of the elongatedgrounding coupler, the first keyed section to insert into an openingdefined by a conductive frame of a photovoltaic (PV) module; and asecond section at the second end, the second section to mate with an endof a conductive cross rail member of the PV module.
 32. The groundingcoupler of claim 31, wherein the length comprises a slender length todefine a cabling channel with the conductive frame and the conductivecross rail member, wherein a first sidewall of the cabling channel isdefined by the conductive frame of the PV module, a second sidewall ofthe cabling channel is defined by the end of the cross rail member, anda bottom of the cabling channel is defined by the length.
 33. Thegrounding coupler of claim 31, wherein the second section comprises asingle wall key.
 34. The grounding coupler of claim 31, wherein thefirst keyed section is arranged to insert into a corner defined byplural conductive frame members of the conductive frame or to insertinto a length of a conductive frame member of the conductive frame. 35.The grounding coupler of claim 31, wherein the first keyed section isarranged to insert into a spline opening, wherein the opening defined bythe conductive frame comprises the spline opening.
 36. The groundingcoupler of claim 31, wherein the opening is shaped as a splined hole.37. The grounding coupler of claim 31, wherein the conductive cross railmember is shaped as an I beam and has at least two flanges, each flangeprojecting at an acute angle from the upright web of the cross-railmember.